Soft capsule based on starch and a method and device for the production thereof
11160760 · 2021-11-02
Assignee
Inventors
Cpc classification
B29C43/44
PERFORMING OPERATIONS; TRANSPORTING
C08L2666/26
CHEMISTRY; METALLURGY
C08L3/02
CHEMISTRY; METALLURGY
C08L3/00
CHEMISTRY; METALLURGY
B29C43/003
PERFORMING OPERATIONS; TRANSPORTING
C08L3/00
CHEMISTRY; METALLURGY
B29K2003/00
PERFORMING OPERATIONS; TRANSPORTING
B29C2043/486
PERFORMING OPERATIONS; TRANSPORTING
A61J3/072
HUMAN NECESSITIES
C08L2666/26
CHEMISTRY; METALLURGY
International classification
A61J3/07
HUMAN NECESSITIES
C08L3/02
CHEMISTRY; METALLURGY
B29C43/44
PERFORMING OPERATIONS; TRANSPORTING
C08L3/00
CHEMISTRY; METALLURGY
B29C43/00
PERFORMING OPERATIONS; TRANSPORTING
A61K9/48
HUMAN NECESSITIES
Abstract
A method for producing starch soft capsules comprises the following steps: preparing a mixture comprising starch, plasticizer and water, wherein more than 50 weight percent of the starch is present in the form of particles of granular starch; shaping the mixture to form a film in a shaping process; solidifying the mixture by increasing the temperature of the mixture during and/or after the shaping process by more than 5° C.; and shaping the film to form a soft capsule. Soft capsules produced by this method have starch particles bonded to one another. A device for performing this method comprises a shaping device to enable shaping of the starch material to form a film, and a heating device to perform a heat treatment to destructure the starch during and/or after the shaping. It comprises a rotary die device.
Claims
1. A soft capsule shell comprising: a) 15 to 55 weight percent of plasticizer; b) >40 weight percent of starch subtracting the plasticizer; c) 0.1-25 weight percent of water of a total weight; d) up to 20 weight percent of thickener, after subtracting the plasticizer; and e) up to 10 weight percent of carrageenan or carrageenans, after subtracting the plasticizer; wherein the starch of the soft capsule shell comprises at least 30 percent starch particles that are destructured, wherein the destructured starch particles are bonded to one another, wherein the destructured starch particles are insoluble in water and are recovered by sedimentation after dissolving the soft capsule shell in water for 30 min at 70 degrees Celsius, and wherein the starch of the soft capsule shell has a weight-average molecular weight of at least 2,500,000 g/mol.
2. The soft capsule shell of claim 1 wherein said soft capsule shell comprises a matrix of the destructured starch particles bonded to one another.
3. The soft capsule shell of claim 1 wherein the soft capsule has a proportion of at least 35 weight percent solids content, which are recovered after dissolving the soft capsule at 70 degrees Celsius by sedimentation.
4. The soft capsule shell of claim 1 comprising additives and adjuvants.
5. The soft capsule shell of claim 1 wherein the starch of the soft capsule shell has a weight-average molecular weight of at least 3,000,000 g/mol.
6. The soft capsule shell of claim 1 wherein the starch of the soft capsule shell has a weight-average molecular weight of at least 4,000,000 g/mol.
7. A soft capsule shell comprising: a) 15 to 55 weight percent of plasticizer; b) >40 weight percent of starch, after subtracting the plasticizer; c) 0.1-25 weight percent of water of a total weight of the soft capsule shell; d) up to 20 weight percent of thickener, after subtracting the plasticizer; and e) up to 10 weight percent of carrageenan or carrageenans, after subtracting the plasticizer; wherein said starch of the soft capsule shell comprises starch particles that are destructured, wherein the destructured starch particles are bonded to one another, wherein the destructured starch particles are insoluble in water, wherein the amount of destructured starch particles recovered by sedimentation after dissolving the soft capsule shell in water for 30 min at 70 degrees Celsius, is at least 25% of the dry weight of the soft capsule shell, and wherein the starch of the soft capsule shell has a weight-average molecular weight of at least 2,500,000 g/mol.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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EXAMPLES
(14) The recipes for the examples are shown in Table 1. Casting mixtures of 10 kg each were prepared. The viscosity of the casting mixture, the mechanical properties and the recovery of the starch are also shown in Table 1.
(15) In all attempts to produce soft capsules, completely transparent soft capsules of a good quality were obtained; in particular, they had dimensional stability, had very good welds, were simple to clean and to dry.
(16) In all the inventive examples, microscopic analysis revealed that the starch films were constructed of densely packed destructured starch grains (<5% birefringent starch grains) and the films could be dissolved into these components again in water, i.e., after disintegration of the films, the destructured starch grains could be detected again in water and their weight could be determined (recovery method no. 1).
(17) Disintegration of the soft capsules in 0.5% hydrochloric acid was determined in an agitated bath at 37° C. on soft capsules that had been dried to a water content of approximately 10% after production and had then been stored for 20 days at 33% atmospheric humidity. The release of the content of the soft capsules occurred after less than 20 min in all examples.
Example 1
(18) According to recipe 1, the water and plasticizer were first added to a heatable and evacuable vessel equipped with a stirrer at room temperature and these two components were then mixed at 100 rpm. Next starch S1E which was extruded under very gentle conditions at a water content of 35% was added and dissolved in the mixture of water and plasticizer for 5 min at 100 rpm. The extruded starch S1E was prepared from dry extrudate (based on the starch S1) by means of a beater mill and had a particle size distribution in the range of 30-150 μmm, as well as a 10% short-chain amylose content (this short-chain amylose was obtained from tapioca starch by complete debranching by means of pullulanase and had a number-average of the degree of polymerization DPn of 25).
(19) To this mixture was then added the granular starch S1 which had a weight-average molecular weight M.sub.w of 30,100,000 g/mol and dispersed therein at 100 rpm for 5 min after which this mixture was heated to 45° C. and degassed for 5 min at 100 rpm by applying a vacuum (removing air bubbles). The dynamic viscosity of this mixture at this temperature was 5.7 Pas at a shear rate of 1.1/s.
(20) The hot mixture was then processed by means of an inventive casting device to form a film. This device is illustrated in
(21) The drum (11) consists of a metal cylinder with a diameter of 50 cm which was heated to the temperature TZ of 105° C. by means of a heating fluid. The rotational speed n of the drum was 0.6 revolution per minute. The casting temperature TG of the mixture was 45° C. The mixture was cast to form a film (16) with a width of 25 cm and a thickness of 0.7 mm by means of the spreader box (12) on the rotating metal cylinder. The cast film (16) was covered by the corotating Teflon belt (14) over ¾ of the circumference, so that the water content in the film would remain constant. After a ¾ revolution, the film was detached from the metal cylinder and conveyed further to a rotary die device (30) of CS-J1-500R from Chang Sung, in which it was processed further at 2 rpm of the rotary dies to form soft capsules of the shape/size oval #10, filled with soy oil (see
(22) A light microscopic image of a starch film which was stored over sodium bromide for 7 months (relative atmospheric humidity 58%) is shown in
(23) The modulus of elasticity values of films from Example 1, which were stored for 2 weeks at relative atmospheric humidities of 33%, 43%, 57% and 75%, were 23 MPa, 3.4 MPa, 3.7 MPa and 3.3 MPa, whereas the modulus of elasticity values of films having the same composition but produced by extrusion in the longitudinal direction and at the same atmospheric humidities were 4.5 MPa, 0.7 MPa, 0.9 MPa and 0.4 MPa.
Example 1a
(24) Example 1 was repeated. The extruded starch S1E and the granular starch were mixed together with the mixture of water and plasticizer. It was found that the sequence in preparation of the casting mixture had no effect on further processing or product properties.
Example 1b
(25) Example 1 was repeated. The finished casting mixture was stored for two hours at room temperature before further processing without having any effect on the further processing or the product property.
Example 1c
(26) Example 1 was repeated. The finished casting mixture was stored for two hours at 45° C. before further processing without having any effect on further processing or the product property.
Example 2
(27) Like Example 1, but instead of 38% water the casting compound had a water content of 35%. The temperature of the drum was set at 108° C. The mass temperature of the film on the drum after ¾ revolution was 93° C.
Example 3
(28) Like Example 1, but instead of 38% water, the casting compound had a water content of 41.1%. The temperature of the drum was set at 103° C. The mass temperature of the film on the drum was 89° C. at ¾ revolution.
Example 4
(29) Like Example 1, but the amount of extruded starch S1E in the casting compound was increased from 2.28% to 4.49% so that the dynamic viscosity at 45° C. and a shear rate of 1.1/s increased from 5.7 Pas to 21 Pas. The temperature of the drum was set at 105° C. The mass temperature of the film on the drum was approximately 90° C. at ¾ revolution.
Example 5
(30) Like Example 1, but the hydroxypropylated crosslinked tapioca starch S1 was replaced by the native tapioca starch S2, and the starch S1E was replaced by the pregelatinized starch S2P. The temperature of the drum was set at 111° C. The mass temperature of the film on the drum after ¾ revolution was approximately 96° C.
(31) Before processing, the starches S2 and S2P had a weight-average molecular weight M.sub.w of 22,690,000 g/mol and the starch extracted from the soft capsules produced therewith had a molecular weight M.sub.w of 21,340,000, i.e., the molecular weight was only minimally reduced in production of the soft capsules (cf.
Example 6
(32) Like Example 1, but the glycerol content was increased. The temperature of the drum was set at 102° C. The temperature of the film after ¾ revolution was 88° C.
Example 7
(33) Like Example 1, but the hydroxypropylated crosslinked tapioca starch S1 was replaced by the native waxy potato starch S4. The temperature of the casting mixture was 40° C. The temperature of the drum was set at 102° C. The temperature of the film after ¾ revolution was 87° C.
Example 8
(34) Like Example 1, but the hydroxypropylated crosslinked tapioca starch S1 was replaced by the hydroxypropylated potato starch S5, and the starch S1E was replaced by the pregelatinized hydroxypropylated potato starch S5P. The temperature of the casting mixture was 40° C. The temperature of the drum was set at 101° C. The temperature of the film after ¾ revolution was 86° C.
(35) The starches S5 and S5P had a weight-average molecular weight M.sub.w of 13,530,000 g/mol before processing and the starch extracted from the soft capsules produced therewith had a molecular weight M.sub.w of 13,490,000 at a first measurement, 15,460,000 at a second measurement, i.e., the molecular weight underwent practically no change in production of the soft capsules. The apparent increase in molecular weight in the second measurement could be attributed to the fact that the accuracy of molecular weight measurements is limited at these high molecular weights.
Example 9
(36) Like Example 1, but the extruded starch S1E was replaced by the pregelatinized starch S1P.
(37) The starches S1 and S1P have a weight-average molecular weight M.sub.w of 30,100,000 g/mol. The molecular weight analysis of the starch in the corresponding soft capsules revealed a molecular weight M.sub.w of 21,340,000 g/mol in a first measurement and a molecular weight M.sub.w of 20,220,000 g/mol in a second measurement, i.e., the molecular weight was reduced only slightly by the process. In particular in comparison with the extrusion method where the starch S1 had a molecular weight M.sub.w of only 920,000 g/mol, although it was extruded under the gentlest possible conditions, i.e., at a high water content and low shear rates.
Example 9a
(38) Example 9 was repeated. But, the extruded starch S1E was replaced by the starch S1 (as dissolved starch) and after adding this starch S1 to the mixture of water and plasticizer, this starch S1 was destructured in this mixture by heating to 90° C. After subsequent cooling to a temperature below 45° C., the granular starch S1 was then added (as granular starch). This had no effect on the following process and the product properties.
Example 9b
(39) Example 9a was repeated. To avoid cooling, the method was simplified by destructuring the starch S1 (as dissolved starch) in only a portion of the water-plasticizer mixture and then adding the rest of water and plasticizer at room temperature to lower the temperature to below 45° C.
Example 10
(40) Like Example 9. But the pregelatinized starch SIP was replaced by the pregelatinized starch S6P. Here again, the same procedures could be used as those described in Examples 9a and 9b in order to destructure the starch S6 (as dissolved starch).
Examples 11 to 13
(41) Like Example 1. But in these examples, the dissolved starch S1E was replaced by thickeners V1, V2 and V3, so that the disintegration behavior of the starch soft capsules in an acid aqueous medium could be accelerated. To dissolve the thickeners V2 (xanthan gum) and V3 (locust bean gum) in the mixture of water and plasticizer, the mixture of water, plasticizer and polysaccharide was heated to 90° C. as in Example 9a and was then cooled to a temperature below approximately 45° C. before adding the granular starch. Here again, the same variant can be used as in Example 9b to prevent active cooling of the mixture of water, plasticizer and dissolved polysaccharide.
Examples 14 to 16
(42) Like Example 1. But in these examples, the dissolved starch S1E was replaced by various tapioca dextrins S7, S8 and S9, so that the disintegration behavior of the starch soft capsules in an acid aqueous medium could be accelerated. To dissolve the dextrins S7 and S8 in the mixture of water and plasticizer, the mixture of water, plasticizer and polysaccharide was heated to 90° C. according to Example 9a and then cooled to a temperature below approximately 45° C. before adding the granular starch (starch 1 according to Table 1). Here again, the same variant can be used as in Example 9b to prevent active cooling of the mixture of water, plasticizer and starch.
Example 17
(43) With all the starch soft capsules obtained from Examples 1 through 17, the original starch particles could be recovered by placing them in water and visualized under a microscope by staining using Lugol's solution.
(44) A light microscopic image of the unprocessed granular tapioca starch S1 from Example 1 is shown in
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Example 18
(47) Example 17 was repeated with the potato starch S5 and the soft capsules according to Example 8.
(48) A light microscopic image of the unprocessed starch S5 from Example 8 under crossed polarizers is shown in
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(50) They are like the starch grains in
Example 19
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Example 20
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Example 21
(54) The molar-mass distributions of the unprocessed starch S2 and the starch S2 that was processed to yield an inventive soft capsule according to Example 5 were compared with one another. To do so, the starch sample and/or the soft capsule sample was dissolved by pressure-cooking under defined conditions in a mini autoclave, and the molar-mass distribution of the molecularly dispersely dissolved starch was investigated by means of GPC-MALLS.
(55) To do so, the starch samples were suspended in water with a concentration of 3 weight percent dry substance. This suspension was heated while stirring in a mini autoclave. After reaching 150° C., the temperature was maintained for 20 minutes. Next the solution was cooled to 60° C., diluted to 0.3 weight percent, filtered through a 5 μm membrane filter and measured on the GPC-MALLS.
(56) The resulting molar-mass distributions are shown in
(57) Measurement Methods
(58) Dynamic viscosities were determined with the help of a Brookfield viscometer of the type LVDV-I+ at a shear rate of 1.1/s (5 rpm, spindle 25) and the stated temperatures.
(59) The mechanical properties (elongation at break, modulus of elasticity) were measured on an Instron 5542 test system according to ISO 527.
(60) Water contents were measured by drying over phosphorus pentoxide at 80° C. for 48 hours.
(61) The GPC-MALLS was performed by means of an Alliance 2695 separation module from the company Waters, DRIDetector 2414 from the company Waters and a Dawn-HELEOS MALLS detector from Wyatt Technologie Inc., Santa Barbara, USA, at a wavelength 1=658 nm and a K5 flow-through cell. Columns: SUPREMA-Gel column set, exclusion limits S30000 with 108-106, S1000 with 2×106-5×104, S100 with 105-103. Eluent: DMSO with 0.09M NaNO.sub.3, temperature: 70° C., analysis: Astra Software 5.3.0.18. A refractive index increment do/dc of 0.068 was taken for all samples.
(62) The determination of the insoluble fraction in the film was performed as follows: first the dried soft capsules were stored for 2 months at 57% atmospheric humidity. A quantity of 100-150 mg (dry matter M0) in the form of a piece of film of the soft capsule shell of 0.5 mm thickness was swollen and/or dissolved together with 7 g demineralized water at 70° C. in a test tube for 30 min while stirring slowly with a magnetic stirrer. Then the test tube was centrifuged until the undissolved components had sedimented and the supernatant had become clear. The supernatant was then decanted. Next 7 g demineralized water was added and stirred with the sediment then centrifuged again and finally decanted. This procedure was repeated again to be sure that there were no longer any soluble constituents in the sediment. This sediment consisted of undissolved starch in the case of a film consisting of starch and plasticizer. Finally the sediment was dried for 48 hours at 80° C. over phosphorus pentaoxide and the dry mass (M1) were determined. The proportion of the mass that could be recovered after the dissolving process was thus obtained as 100×M1/M0 in weight percent. The proportion of starch that can be recovered after the dissolving process is obtained as follows for a starch film consisting of starch and plasticizer as 100×M1/(M0×(1−(WM/100)) in weight percent, where WM is the amount in weight percent of the plasticizer of the dry mixture. As a rule, the starch film still comprises at most minimal amounts of insoluble components, e.g., pigments (typically <0.5%) or fillers such as titanium dioxide (typically <1.5%) in addition to the starch particles. In case of need such components are subtracted from the dry matter M0 and the mass M1.
(63) TABLE-US-00001 TABLE 1 Fresh film Recipe of the casting mixture Viscosity of Modulus Granular Dissolved Thick- the casting of Exam- Granular Dissolved Thick- starch starch SCA ener H.sub.2O WM mixture elasticity Elongation H.sub.2O Wg. ple starch starch ener [%] [%] [%] [%] [%] [%] [° C.] [Pas] [MPa] [%] [%] [%] 1 S1 S1E — 38.97 2.28 0.25 — 38.0 20.5 45 5.7 0.03 386 36.5 86.3 2 S1 S1E — 40.85 2.39 0.27 — 35.0 21.5 45 14 0.04 430 34.2 87.2 3 S1 S1E — 37.06 2.17 0.24 — 41.1 19.5 45 2 0.02 531 40.0 86.7 4 S1 S1E — 36.54 4.49 0.50 — 38.0 20.5 45 21 0.03 420 37.0 82.3 5 S2 S2P — 38.97 2.28 0.25 — 38.0 20.5 45 2.8 0.03 452 36.8 92.1 6 S1 S1E — 39.08 2.29 0.25 — 33.5 24.9 45 21 0.02 510 33.1 91.5 7 S4 S1E — 38.98 2.28 0.25 — 38.0 20.4 40 8 0.14 148 35.8 73.4 8 S5 S5P — 39.42 1.88 0.21 — 38.0 20.5 40 4.3 0.03 430 36.5 64.2 9 S1 S1P — 39.43 2.09 — — 38.0 20.5 45 11 0.04 421 36.7 88.4 10 S1 S6P — 39.45 2.09 — — 38.0 20.5 45 4 0.02 523 34.3 79.5 11 S1 — V1 41.11 — — 0.41 38.0 20.5 45 35 0.05 440 37.9 89.2 12 S1 — V2 41.32 — — 0.21 38.0 20.5 45 17 0.04 508 37.7 91.2 13 S1 — V3 41.11 — — 0.41 38.0 20.5 45 20 0.04 467 37.8 92.5 14 S1 S7 — 33.24 8.30 — — 38.0 20.5 45 13 0.03 507 37.2 88.4 15 S1 S8 — 33.23 8.30 — — 38.0 20.5 45 10 0.02 563 37.4 86.2 16 S1 S9 — 36.56 5.02 — — 38.0 20.5 45 22 0.02 499 35 84.7 Legend to Table 1 granular starch: S1 hydroxypropylated crosslinked tapioca starch (Creamtex 75725 from Cerestar) S2 native tapioca starch (from Cerestar) S4 waxy potato starch (Eliane 100 from AVEBE) S5 hydroxypropylated potato starch (Emden KH 15 from Emsland) dissolved starch: S1E starch S1, extruded, comprising 10% short-chain amylose S1P starch S1, pregelatinized S2P starch S2, pregelatinized S5P starch S5, pregelatinized S6P hydroxypropylated starch (Emcol H7 from Emsland), pregelatinized S7 tapioca dextrin (Cleargum TA 90 from Roquette) S8 tapioca dextrin (Tapioca Dextrin 11 from Tate&Lyle) S9 mixture of 50% starch S1P and 50% tapioca dextrin (Dextrin D-400 from Cerestar) Thickener: V1 guar gum (Meypro Guar CSAA M-200 from Meyhall/Rhodia) V2 xanthan gum (Keltrol HP E415 from Kelko) V3 locust bean gum (Meypro LBG Fleur M-175 from Meyhall/Rhodia) WM: glycerol as plasticizer All percentage amounts are given in weight percent based on 100 weight percent of the total casting mixture. The mechanical properties (modulus of elasticity and elongation) of the fresh film were measured at a temperature of 25° C., 10 min after producing the film. Wg.: recovery according to recovery method no. 1